PFISTERER Customer Magazine
Issue 1 2016
4 Strong players in a new group
8 Green energy in microgrids
www.pfisterer.com
12Flexible plug-in power
transformers across the grid
Legal Notice
Publisher
PFISTERER Holding AG
Rosenstrasse 44
73650 Winterbach
Germany
Tel: +49 7181 7005 0
Fax:+49 7181 7005 565
[email protected]
www.pfisterer.com
Editorial Team
PFISTERER Kontaktsysteme GmbH
Rosenstraße 44, 73650 Winterbach
Harald Cuber, Andreas Dobler, Natalie Fischer,
Volker Janzen, Leif Johansson, Bernhard
Kahl, Peter Kaiser, Michael Keinert, Andreas
Kussmaul, Lena Miunske, Peter Müller,
Martin Schuster, Martin Sossau, Christian
Späth, Frank Straßner
Text concept and text editor
Karolina Kos
www.xyzeiler.de
Sympra GmbH
Agency for Public Relations
Stuttgart
Art Direction
VISCHER & BERNET GmbH
Marketing and Advertising Agency
Stuttgart
© Copyright by PFISTERER
Kontaktsysteme GmbH
PFISTERER
Customer Magazine
Issue 1 2016
2
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4Strong realignment:
in a new group
PFISTERER & LAPP
Insulators lead in insulators
8Decentralized & sustainable
regenerative energy: CrossPower
now makes it possible
12For versatile operation across
the grid: fully pluggable power
transformers at AVU Netz GmbH
18CONNEX innovation for
flexible transformer use:
plug-in bushing for 362 kV
19IXOSIL newcomer:
dry-insulated termination
with surge arrester
Editorial
Growth for strong grids
Michael Keinert
PFISTERER is growing – in output power
on behalf of our customers: The acqui­
sition of LAPP Insulators places us in a
leading position in the insulator world
market, with an unmatched broad range
of products and even more expertise
for advanced complete solutions (page 4).
We are utilizing our more than a century
of experience with power networks in
the new microgrids business. And that
business is taking off with CrossPower:
The hybrid energy system allows the
provision of decentralized regenerative
energy even in remote l­ocations (page 8).
While our tried and tested connection
solutions in the area of high voltage
­continue to expand (pages 18 and 19), the
AVU Netz GmbH power transformers
are being used in flexible ways – across
the grid thanks to CONNEX (page 12).
We hope you enjoy reading about the
­exciting prospects. We are always
­prepared to be an effective partner for
your power network needs!
Best regards,
Michael Keinert
Member of the Board
PFISTERER Holding AG
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3
Concentrated expertise,
complete systems and
future plans
4
CONNECT 2016
In October of last year, PFISTERER
­announced their acquisition of LAPP
Insulators. The merger enables the
company group to move into a leading
position in the world market for
­medium and high voltage insulators.
In an interview, Dr.-Ing. Bernhard
Kahl, General ­Manager of LAPP Insulators and head of the Overhead
­Lines Technology d
­ ivision at Pfisterer,
and Michael Keinert, member of
the Board of Directors at PFISTERER,
provide an outlook on future deve­
lopments and draw initial con­clusions
about the collaboration so far.
Mr. Kahl, Mr. Keinert, you are both experts on high-­
voltage connections. How is the connection between
the two companies going after the first six months?
Bernhard Kahl: The personal interaction with the employees
is very good. We felt a positive working atmosphere from
the very beginning. Naturally, it’s a big undertaking when
two companies of about the same size merge. Our advantage is that the corporate cultures of LAPP Insulators and
PFISTERER are quite similar. The customers’ reaction
has also been uniformly positive. LAPP Insulators had
several changes in ownership, which also included
­financial investors. With PFISTERER we are now part of
«With PFISTERER we are now
part of a family-run, industry
focused company once again.
That engenders trust and
long-term security – and we
are feeling the resulting
momentum now.»
Dr.-Ing. Bernhard Kahl
Managing Director of LAPP Insulators Holding GmbH
a family-run, industry-focused company once again. That
­ ngenders trust and long-term security – and we are exe
periencing the resulting momentum.
Michael Keinert: We are already being broadly perceived
as one company now, which we are very pleased about.
What is important: The previous customer relationships
will continue as usual, both at LAPP Insulators and
­PFISTERER – as innovative partners and reliable suppliers.
We were a
­ lready the two leading technology companies,
and we have only become stronger through the merger:
PFISTERER’s product range now also benefits LAPP
­Insulators’ customers and vice versa. Not all customers
need everything we offer, but our comprehensive expertise
can provide all customers with added value.
LAPP Insulators product range
Transmission & Distribution
Overhead Lines
Transmission & Distribution
Substations
OEM
Porcelain Longrod
Insulators
Porcelain Post
Insulators
Porcelain Hollow Core
Insulators
RODURFLEX Composite
Suspension Insulators
RODURFLEX Composite
Station Post Insulators
SIMOTEC Composite Hollow
Core Insulators
LIKE: LAPP Insulators
Knowledge & Engineering
Porcelain Suspension
Insulators
Medium Voltage Insulators
RODURFLEX Composite
Line Post Insulators
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5
«We are already being
broadly perceived as one
company now, which we
are very pleased about.»
Michael Keinert
Member of the Board of PFISTERER Holding AG
What were PFISTERER’s motives for acquiring
LAPP Insulators?
Michael Keinert: The acquisition was an important
­component of our growth and investment program
“PFISTERER Next Level”, with which we pursue the goal
to grow in familiar areas, but also into new ones. That
­includes the area of overhead lines, and LAPP Insulators
is an ideal match for us, both technologically and
­geographically. The addition significantly expands our
worldwide strategic market presence.
What are the benefits to the customers?
Michael Keinert: PFISTERER and LAPP Insulators are
both acknowledged as technology leaders. Among other
things, the two most distinguished authorities in the
area of insulators, Dr. Frank Schmuck and Dr. Jens Martin
Seifert, are now working together. The synergies for ­
our customers can be found in different areas: a selfcontained product line with plastic composite and
­ceramic insulators, expertise in string construction and
the know-how in d
­ eveloping complete ­insulator sets
from them. That means we can provide depen­dable,
­secure systems to our ­customers. We complement each
other in further areas, for example, at the interface
­between overhead line and cable system technology,
PFISTERER’s second key business.
Bernhard Kahl: PFISTERER always represented the
bench­mark in string construction to LAPP Insulators.
Conversely, the LAPP Insulators management solutions
and development are also having a beneficial effect on
PFISTERER. It may be somewhat challenging at times,
but new perspectives always bring positive impulses. We
already established the LIKE business – LAPP Insulators
Knowledge and Engineering – in 2013 to bundle our expertise. There we consolidate our entire wealth of experience
and knowledge at one central point with the aim of developing complete solutions for our c­ ustomers. Among
others, the gas-insulated bushing product group was created
as a result. Now we can also draw on PFISTERER’s expertise in this area. Furthermore, LAPP I­nsulators has a
high voltage lab that also provides services. PFISTERER
has similar capabilities at their disposal in other areas
and would also like to expand on those services as well.
6
CONNECT 2016
Michael Keinert: Of course, it’s still a bit premature to say
anything definitively, but there will certainly also be new
developments coming out of our joint research, e.g. in the
area of compact lines. Expertise is being bundled here
that no other company in the world can currently match.
We are also already planning new joint solutions regarding air ­insulated substations. LAPP Insulators has deep
knowledge in this area because of the high ceramics
content, whereas PFISTERER has it with plug-in sockets
for transformers.
Bernhard Kahl: We also want to utilize the now increased
importance of overhead line technology in the united
company more for distribution purposes. LAPP Insulators
is the major brand in overhead line technology, especially
in the US. We have deep roots in America and are celebrating
our 100th anniversary there this year. This distribution
Michael Keinert
Member of the Board of
PFISTERER Holding AG
Dr.-Ing. Bernhard Kahl
Managing Director of LAPP
Insulators Holding GmbH
PSISTERER now offers innovative chain design with either silicone or
porcelain insulators
network is now also available to PFISTERER’s
products. On the other hand, PFISTERER has
traditionally had a stronger position in other
countries and is better known in the area of
components, like strings and damping elements.
We may currently have two distribution channel
structures at our disposal, but we complement
each other well and our combined sales force is
not too big. On the contrary, the added manpower
gives us more heft in segments which may not
have been given enough attention before. Naturally,
our competitors are not particularly happy about
the merger.
Mr. Kahl, your enthusiasm for the merger is
quite palpable just from listening to you – is
that correct?
Bernhard Kahl: I have always thought that
PFISTERER was the ideal partner for LAPP
Insulators. The market is a constant challenge –
jointly or separately – but we are definitely
stronger together.
Scan this QR code
for more information.
Porcelain is still the world's the most commonly used insulator
material – now also featured in the product range from
PFISTERER.
PFISTERER and
LAPP Insulators
LAPP lnsulators is the third largest vendor of medium
and high voltage insulators made of porcelain, ceramic
and composition materials in the world. These products
are used in more than 70 countries, particularly in the
area of high voltage and traction current grids, switchgear
systems and transformers. The company grew out of
traditions root-ed in the renowned Rosenthal and Siemens
brands, and reaches back to 1889 in Germany, and to
1916 in the US. In 2001 LAPP lnsulators took over the
production facility of CeramTec in Wunsiedel, Germany,
and acquired Argillon Group’s insulator sector and its
three locations in 2008.
PFISTERER has gained a prominent market position in the
overhead lines (OHL) segment through the purchase of
LAPP Insulators. The meshing of the existing range of
insulation strings and cable and contact systems has
made PFISTERER one of the few vendors worldwide that
is essentially in a position to cover the entire supply
chain for contacting and insulation, from power generation to its distribution, as a one-stop source.
LAPP Insulators has around 1,200 employees worldwide,
and more than half of them work at production sites in
the US (Le Roy, New York state), Romania (Turda) and
Poland (Jedlina). More than 500 employees work at the
headquarters in Wunsiedel and two nearby locations in
Germany, Redwitz and Selb. PFISTERER has production
facilities in Europe, South America and South Africa as
well as sales subsidiaries in another 18 countries in
Europe, Asia, Africa, South America and the US. The
company group employs around 2,700 people in total.
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7
Regenerative energy supply
– any place in the world
A sustainable, reliable energy network
for remote locations based on renewable energy sources: What once seemed
impossible has become p
­ ossible with
CrossPower. PFISTERER has taken the
first step into the world of decentralized
regenerative energy supply with the
development of a h
­ ybrid energy system.
The intelligent management system
combines different energy sources and
balances ­generation and consumption
optimally. In the process, the system
permits a quick set-up of robust energy
networks with fuel savings of up to
50 percent as opposed to conventional
diesel generators.
Even today a stable energy supply should not be taken for
granted. There are many places around the world where
power is either not available at all or is only generated with
the aid of diesel generators. “We generally come ­across
this method of energy generation in emerging and developing
countries, but they even exist in Europe, for example, at
large construction sites or on off-shore platforms”, explains
Michael Keinert, member of the board of PFISTERER
CrossPower helps to help out:
smart energy supply for all types of camps
8
CONNECT 2016
­ olding AG. Large agribusiness complexes like plantations
H
or animal husbandry operations often don’t have a stable
power supply. “Furthermore, there are hotel facilities and
thousands of small islands which are not connected to a
stable grid. They obtain their supply primarily with the use
of diesel generators, as regenerative energy sources aren’t
yet able to provide the necessary supply security through
decentralized networks. The fuel consumption required for
that is extremely high. Therefore, we wanted to develop a
system that makes the use of regenerative energy possible
at any location in the world where an independent, economical
and reliable energy supply is needed,” according to Keinert.
What began as an ambitious idea took on concrete form with
the first CrossPower system deliveries at the beginning of
February. “Our energy system is able to mix any conventional
energy sources, e.g. diesel generators, with renewable
energy to supplement generators in a decen­tralized network
and optimally balance out energy generation as well as
consumption,” as Martin Schuster, Senior A
­ dvisor and responsible project manager at PFISTERER explains. These
isolated energy grids, or so-called micro­grids, reliably ensure
a stable energy supply regardless of weather conditions
and fluctuating energy g
­ eneration. That makes them perfectly
suited for use in remote regions, in mining operations, industrial facilities and research stations. Large quantities of
fossil fuels can be saved in the future with the help of the
CrossPower system. The stable network layout is made
possible by the interaction of intelligent energy management
solutions and state-of-the-art lithium-ion technology. The
In remote places, transport costs for fossil fuels play
an important role. Here, a CrossPower system pays off
very quickly.
The mobile version of CrossPower brings fast reliable
power supply to disaster areas.
centerpiece of the system is made up of a central control
system and high-performance storage batteries to which any
number of generators can be connected. In addition, the entire
CrossPower system can be easily integrated into existing energy
grids and used with diesel generators that are already on hand.
A parallel power generation operation is also possible to compensate for supply gaps in unstable grids.
Stationary and mobile
Besides continuous stationary operation, the system is very
well-suited for mobile applications, e.g. in crisis areas or
refugee camps, because of its compact design. “CrossPower
can be transported quickly to any place on earth. In case of
­catastrophes, our mobile system can be quickly set up as a
scalable temporary energy grid based on renewable energy
sources,” Michael Keinert emphasizes. Transporting fossil fuels
to crisis areas presents major logistics challenges – and
­under certain circumstances even life-threatening ones – as
well as involving high costs. “At the same time, a fast set-up
of working energy networks is the basis for stabilizing the situation quickly and thus allows the population to stay where
they are. The use of available energy sources like wind and sun
provide huge advantages here.”
With an output of up to 1,000 kW, entire settlements can be permanently
supplied with a CrossPower system.
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9
Flexible and intelligent energy management
The particular highlight of the system is the control software
that independently favors renewable energy sources
­according to availability. The diesel generators merely serve
to charge the battery only as needed and always work within
their ideal output range. If both sun and wind energy are low,
the management system first draws on the battery and
utilizes it to the prespecified minimum. The various energy
sources are so well-­coordinated with each other in terms
of their capacity utilization that up to 50 percent fuel savings
are possible. There are also different priority levels avail­
able that can be selected individually both during energy
generation as well as on the part of the consumer and
­monitored by the system. In cases of diesel shortages or
generator breakdowns, for example, important consumers
like surgery units, cold rooms or IT systems will be given
priority automatically over less important ones and s­ upplied
to 100 percent with regenerative sources.
Ultimately, CrossPower provides a stable, consistent p
­ ower
supply, whereby output voltage and frequency can be adapted
to the local requirements – everything from 230 V at 50 Hz
or 110 V at 60 Hz is possible. The system is designed to be
safe to touch and can be set up in close proximity to tents
and working installations. Thanks to the 3G module, the
24 hours – energy requirement and power generation
from various sources
Energy requirement [kW]
Battery charge status [%]
100
25
90
80
70
60
50
12,5
40
30
20
10
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
Energiequelle
Solar energy [kW]
10
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Wind power [kW]
Diesel generator [kW]
Battery [%]
Ladestand [%]
Solarenergie [kW]
Wetterverhältnisse
Proven in practice: the CrossPower System in Hungary.
Environmentally friendly energy for an entire camp.
system can be monitored and maintained remotely over all
mobile phone networks using an encrypted and secure
connection (VPN). In addition, the m
­ obile networks can be
set up quickly and safely without specialists due to
PFISTERER’s modular plug-in Plug&Operate components.
The system itself can be housed in standard containers.
“We were able to bring in and further expand our expertise
as “network professionals” in the development and design
of the system,” says Michael Keinert with satisfaction.
Scan this QR code
for more information.
Tried and tested in practice
and already in use
The first CrossPower system was handed over to the NATO
Energy Security Centre of Excellence in Lithuania at the
beginning of February 2016. Sigitas Mudris, Commander of
the Lithuanian Logistics Commando, expressed his
­satisfaction over the positive collaboration with the German
industry: “PFISTERER was able to design and construct
a highly-complex, very solid system in a very short time.”
It has an output of 150 kW (up to 2,500 kWh per day) and
a storage capacity of 100 kWh. It consists of a control unit,
efficient rechargeable batteries, a wind turbine and solar
panels as well as two diesel generators, which can all be
transported in two 20-inch ISO containers.
The mobile energy system already proved that it was
practicable under realistic conditions last June during the
NATO exercise “Capable Logistician 2015”. A 25-kW system
with a storage capacity of 60 kWh reliably provided a number
of crucial facilities such as IT systems, laboratories and
tent accommodation for the entire exercise. “The demands
on a reliable smart energy power supply in remote regions
and critical zones are high: The systems have to provide
energy reliably around the clock while using locally
available energy sources that are suitable for mobile applications at the same time. We were successful”, says
Martin Schuster, Senior Advisor at PFISTERER.
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11
For economical
transformer operations:
By making all of their
connections pluggable,
CONNEX makes
transformers highly
versatile. AVU Netz GmbH‘s
new 110/10-kV transformers
from SGB are a good
example. With one design
they cover all relevant
connection constellations.
AVU Netz specialists Nico
Krächter and Volker Jost
show this on a tour of their
territory with PFISTERER
customer service agent
Volker Janzen
(small picture below,
from left to right).
Power transformers that can do longterm service anywhere in the network
– the West German network operator
AVU Netz GmbH is achieving this aim in
the interest of efficient energy supply.
The proven key technology it is using here
is the CONNEX flexible connection system.
On a brief tour of three substations,
HV system experts Nico Krächter and
Volker Jost explain CONNEX’s advantages with an eye to changes affecting
the mains supply.
«CONNEX is a modular overall
system that provides an
economical solution for all the
relevant connection constell­
ations in our network.»
Nico Krächter
Head of the high-voltage system team
at AVU Netz GmbH
An der Drehbank 18, Gevelsberg. The street address of AVU
Netz’s headquarters recalls one of the main drivers of the
Industrial Revolution (“Drehbank“ means “lathe”), because
lathes were the precursors to engine lathes. And engine lathes
“Versatile transformers
for every site“
12
CONNECT 2016
Annen
EssenBurgaltendorf
Witten
Bochum
For reliable power supply: AVU
Netz's power network area in the
Ennepe-Ruhr district in the heart
of North Rhine Westphalia. Power
transformers equipped with CONNEX
play a key role in modern electricity
supply for more than 45,000 households. And AVU is reliable: its average
annual break in service of 3 minutes
per customer is well below the
Germany-wide average of around 16
minutes.
Kruckel
Witten
Nocken
Herdecke
Hattingen
Steinenhaus
Hattingen
Wetter
Volmarstein
Sprockhövel
Rocholz
Haßlinghausen Gevelsberg
Gevelsberg
Schwelm
Voerde
Altenvoerde
Ennepetal
Mitte
Schwelm
AVU Network
Breckerfeld
Breckerfeld
Külchen
downstream network operators
110-kV lines
110-kV lines
Rohland
110-kV substations
30-kV substations
were what enabled precision components for production
machines and motors to be made economically on a mass
scale. Efficiency in times of change is also high on the
agenda of AVU Netz. In its view, efficiency should also apply
to a reliable electricity supply that meets modern standards. With an average annual break in service of 3 minutes
per customer, the company lies well under the Germanywide average of around 16 minutes.
Proven standards. New concept.
“CONNEX cable connections have been used in the AVU network for 20 years now, in both gas-insulated switchgears and
transformers,” reports Krächter, who heads the high-voltage
system team. “There are good reasons for this. Let’s take
two: they can be installed without inter vening in the system’s
interior workings, and they are completely touchproof. And
then there’s another crucial benefit: CONNEX is a modular
A wholly-owned subsidiary of AVU AG, AVU Netz operates
its own electricity, natural gas, and water networks for the
Ennepe-Ruhr district in the heart of North Rhine-Westphalia.
Including links to adjacent networks, its power lines alone
have a combined length of more than 3,500 kilometers,
and its high-voltage network with thirteen 110-kV substations
covers an area of approximately 333 square kilometers.
This is the territory of Nico Krächter, Volker Jost, and their
team, whose main job consists of planning and building
high-voltage systems. Their work is made easier when power
transformers are equipped with CONNEX technology.
Since 2014 AVU Netz has been converting its 110-kV lines
on the southern ring from oil and gas-insulated to XLPE
cable technology. At the same time, it is replacing a number
of older systems with new ones. The network operator’s
planners had all of these measures in mind when they defined
the specifications for the 110/10-kV transformers to be
acquired. Their practical experience, both in modernizing
networks and with the CONNEX connection system, also
played a role.
Multiple plug-in connections, all touchproof: Fully insulated
MV-CONNEX size 3 cable connections on the transformer's lower
voltage side: CONNEX quadruple-contact elbow bushings are
used for the phase connections, and the CONNEX double-contact
elbow bushing for neutral point treatment.
CONNECT 2016
13
overall system that provides an economical solution for all
the relevant connection constellations in our network.”
“The connections in every network vary depending on where
and when they were installed,” explains Jost. As the
­project head, he frequently oversees network connection
work for transformers and high-voltage cable systems.
“This works best when you know the possibilities and limi­
tations of the equipment you’re using, and if you can use
it under different conditions in uncomplicated ways.”
All of these factors are reflected in the new 110/10-kV trans­
formers of the 50-MVA power class. There are three of
them with an identical design. They were made by SGB to
meet the network operator’s specifications – a wellthought-out combination of proven AVU network standards
with a new interface concept that consists of integrating
CONNEX sockets into the transformers at all phases and
star points. That allows different dry-in­sulated CONNEX
components to be plugged into them. Jost and Krächter
describe the advantages of all-round plug-in power
­transformers in detail where it really counts – at the sites
where they are used.
Sensible exception. Safe connection.
We start at the Witten substation in the adjacent network
operated by the Witten municipal utilities. The AVU network
feeds 10-kV power into it as an upstream supplier. Since
the autumn of 2015, the power has come from one of the
three new SGB transformers. It stands outdoors on a cement platform. Everything appears to be normal. But not
Clever integration of new and existing technology: Volker Jost
shows how no site conversions are needed at the Witten
substation, even given its unique constellation. HV-CONNEX
bushings are installed on the higher voltage side of the new
SGB transformer which allow it to be connected to an indoor
GIS via pre-existing gas-insulated wall bushings.
Outdoor connection with
mobility options: Classical use of
HV-CONNEX size 5-S bushings to
connect a transformer and an outdoor
switchgear at the Schwelm substation.
The bushings' horizontal configuration
allows them to be transported
in mounted form in compliance
with Deutsche Bahn (German
Rail) standards. For other modes
of transport they can be removed
without intervening in the system's
interior workings.
14
CONNECT 2016
«The more transformers are
equipped with CONNEX, the
more flexible our system is
in general.»
Volker Jost
Project head on the high-voltage system team
at AVU Netz GmbH
quite. Jost points to a flat-roofed building next to it. “There's
a gas-insulated switchgear in there. The usual way of connecting it these days would be by cable to the transformer.
But we're making an exception to that practice here.” He
turns toward the higher-voltage side of the transformer.
Three HV-CONNEX bushings stick out.
Lines connect these bushings via surge arresters to SF6
gas-insulated wall bushings mounted on the outside of the
flat-roofed building. The switchgear inside the building
docks through the wall via an SF6 gas-insulated extension.
“This was a special construction from the 1980s,” says
Jost. “It continues to work perfectly, and the new transformer
can be easily integrated. So why should we do some type
of complicated reconfiguration?”
Krächter moves his hands like an imaginary scale. “When you
transport mobile transformers in compliance with Deutsche
Bahn (German Rail) standards, you typically have horizontally
mounted bushings, and these have t­ raditionally been premounted porcelain bushings. As you can see on our SGB
transformer again, plug-in HV-CONNEX bushings can
also be installed horizontally. That increases our flexibility
for all other modes of transport too, such as flatbed trucks.
Just like with the CONNEX cable connections, if you have
to uninstall them you can do so without opening up the
transformer. Furthermore, regardless of where you end
up sending the transformer, it’s easier to protect sep­
arated bushings from mechanical damage.”
“And regardless of where you send the transformers, they’re
equipped for different situations,” adds Jost. “At many of
our transformer stands we run the cables on the ground
to save space. So we've had SGB install a s
­ econd HV-­
CONNEX socket facing straight down for each higher voltage
phase. This lets us make a cable connection to a gas-­
insulated switchgear, or to an air-­insulated one via additional
outdoor cable terminations. In addition, we're flexible with
respect to the higher-­voltage star point, which we can also
handle via a cable connection instead of a bushing. And
for other constel­l ations, the same CONNEX interface can
be used completely ­differently, namely with a CONNEX
plug-in surge arrester. That in turn would have two advantages: there’s optimal surge protection right there at the
equipment, and it’s touchproof there too.”
Krächter nods and adds, “Regarding site-specific solutions:
All three SGB transformers stand outdoors. If their MV
conductor connections were uninsulated, small animals
could bridge them and trigger a secondary short circuit.
We've eliminated this typical operating risk with MV-CONNEX
cable connections, which are fully insulated and therefore
touchproof. They protect the equipment, people, and animals
at the same time.”
Jost and Krächter have concentrated on safety from the word
go. They both completed training programs in energy
­electronics, studied engineering, and have more than 15 years
of professional experience. We now head to the second site
where they explain relevant interface-related aspects for
operating network transformers.
Streamlined transmission. Variable at sites.
An air-insulated substation in Schwelm extends over an
enclosed area of grass and gravel. The second SGB transformer is connected to it by three HV-CONNEX bushings.
A fourth HV-CONNEX bushing serves to connect its highervoltage star point with a ground fault deletion coil. “It’s
a standard configuration,” says Krächter, “and CONNEX
gives you valuable leeway.”
Variable star point use: CONNEX is also used on the highervoltage star point for the new SGB transformers, like at the
Schwelm substation. An HV-CONNEX socket enables a line connection
to a Petersen coil. Other measures can be taken immediately
for divergent system configurations. Instead of a bushing, the
HV-CONNEX socket installed on the transformer side can
­accommodate either an HV-CONNEX separable cable connector
or an HV-CONNEX surge arrestor.
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15
In short, there are many options. AVU Netz has already made
use of a number of them with its new SGB transformers.
Others are possible with the older transformers. The last
stop on our tour shows both of these possibilities at work.
One design. Three connection variants.
The Altenvoerde substation. A simple cement structure in
Wehrstraße. AVU Netz has invested around 3.4 million euros
in it. The building is new, as is the equipment it houses: a
gas-insulated switchgear (GIS) with digital conductor technology. It replaces a GIS from the year 1969, which was
state-of-the-art back then. The new switchgear started
operating at the end of 2014, and the third of the three new
SGB transformers was connected in February 2015.
what the system calculations yield for this specific constellation, it could be necessary to install surge arresters
directly on the transformer. And plans call for the second
transformer, which is currently running as a stationary reserve,
to be converted to a mobile reserve so it can be used throughout the network.”
“There's another important aspect in this context,” notes Jost
in conclusion. “Mobile transformers in particular should be
able to start up quickly and safely wherever they're needed.
CONNEX supports that too. With test and transition equipment that can also be installed without complex oil work.
To sum it up: CONNEX enables technically sound, versatile
transformers for every site.”
Krächter points to the higher voltage side. “Here you can see
the type of connection that Volker was describing earlier.
HV-CONNEX sockets on the ground have cable connections
for the new GIS. The sockets above them for the bushing
option are closed with CONNEX dummy plugs. All the other
CONNEX interfaces are used like those at the Schwelm
and Witten substations. With one transformer design and
one connection system, we are already covering three
constellations just for the higher voltage phases: two standard ones plus the special case of a bushing connection
between the transformer and the GIS.”
Modern conversion. Systematic approach.
“Speaking of efficiency, when surrounding systems are updated it can also be a good idea to furnish the existing
transformers with modern connections,” says Jost and
points to the adjacent transformer station. “Like this
110/10-kV transformer and another one here at this site.
Both had wet terminations on the higher voltage side.
Because of our conversion to XLPE cables, we would have
had to convert the transformer connections to the new
GIS anyway. That's why we're using HV-CONNEX cable
connections here. They not only make sense from a
technical perspective, they’re also a good idea for the
future: the more transformers are equipped with CONNEX,
the more flexible our system is in general.” And there's a
lot going on. A new 110-kV XLPE cable is also being laid
between the Altenvoerde and Voerde substations. The two
power transformers in Voerde are scheduled to be converted
in 2018. “CONNEX will make sense there too, on account
of what we plan to do afterwards,” says Krächter. “One
transformer will stay in Voerde and be connected to the new
GIS here in Altenvoerde via the new XLPE cable. That would
be the 'outsourced transformer' scenario. Depending on
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CONNECT 2016
Smart double: With two HV-CONNEX sockets for each higher
voltage phase, the new SGB transformers are superbly equipped
for different connection constellations. Nico Krächter points to one
of them at the Altenvoerde substation. The HV-CONNEX sockets
installed above on the transformer for horizontal bushings are not
needed at this site and so are closed with voltage-proof dummy
plugs. By contrast, the ones below hold HV-CONNEX plugs for a
ground cable connection to the new GIS in the adjacent building.
Universal plug-in
options
The core of the CONNEX system consists of
its sockets – circled in red here for better
visibility and to show their different installation
positions on the new transformers for AVU
Netz GmbH. The sockets are installed in the
transformer connection housings as universal
interfaces for plug-in CONNEX components.
For power transformers with the same design
that can be used throughout the network, AVU
Netz uses two HV-CONNEX sockets per higher
voltage phase: the upper ones accommodate
HV-CONNEX bushings for outdoor connections
(above) – in a horizontal position to enable
transport in compliance with German rail
standards. The lower sockets facing straight
down (below) accommodate HV-CONNEX cable
terminations for the ground cable connections
generally used in the AVU network. Whichever
sockets are not used are closed with voltageproof CONNEX blind sockets (shown hovering
next to or below their respective socket,
depending on which connection option is used).
Adaptable based
on need
An interface concept for all-round plug-in
power transformers has the potential to be
conveniently adapted to future needs. This
diagram of the same transformer design
shows one example: if the connection housing
is installed the other way around on the
transformer, its integrated HV-CONNEX
sockets (red circles indicate installation type)
open new cable connection possibilities for
each higher voltage phase, including directly
installed HV-CONNEX surge arresters – a
variant that could make sense if the transformer
is to be connected to a switchgear at a greater
distance such that it no longer has sufficient
surge protection.
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17
New: Pluggable
CONNEX bushing
for 362 kV
Mobile power transformers for emergencies – this innovative concept
increases the operational reliability
of power grids. The prerequisite for
this are versatile transformers that
are easily transported and installed
quickly. It has now become possible
with the pluggable HV-CONNEX bushing
size 7-S, the first plug-in type bushing
for high voltage levels up to 362 kV.
A secure electricity supply depends on power transformers
that work properly. Yet risks like operational disruption, environmental factors or physical attacks can lead to outages.
Mobile transformers are a forward-looking solution to
being prepared for those kinds of emergencies. The RIPinsulated, pluggable HV-CONNEX bushing permits them to
be built so compactly that they can be easily transported by
truck. The on-site set-up is very secure thanks to the
plug-in system, as the transformer and the bushings are
already inspected at the factory and don’t have to be
opened again. As a result, the installation can be successfully completed in a very short time, so that only a few
days go by between the outage and the start-up operation.
A special feature of the size 7-S as compared to the
previous CONNEX bushings is the high ampacity, which
attains a rated current of 2,000 A. In addition, a
technology was developed for the high voltage level,
which is protected by an FRP body at the RIP bushing.
The first bushings for mobile transformers in the US were
delivered in November 2015. The HV-CONNEX bushings
product range is due to be developed in the next step for
voltage levels of up to 420 KV.
The advantages
at a glance
n
n
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CONNECT 2016
Transformers become mobile and versatile
Easy and quick to install
RIP-insulated and pluggable
For extra high voltage to 362 kV
Increase the operational reliability of
power grids and lower installation costs
at the same time – IXOSIL EST SUB
with surge arrester makes it possible.
The new product solution for voltage
levels from 123 kV to 170 kV combines
a dry-insulated cable termination
with a surge arrester in one unit for the
first time.
The newcomer in the IXOSIL range combines the advantages
of dry-insulated terminations with an integrated dry and
gas-free surge arrester. The insulation is made exclusively
with the solid material silicone. Environmental pollution
or operational safety issues due to leakage are completely
ruled out. The terminations don’t contain any fluids,
therefore they are easier to transport and faster to install
than conventional terminations.
The components of the combination product are independent
of each other. That means the cable termination can be
fitted very accurately on the ground and subsequently
mounted to the already installed surge arrester in a
vertical position. It serves the cable termination as a support
so additional support elements are not required. The
individual elements fulfill the IEC 60840 and IEC 60099
standards. An optional surge counter is available for the
surge arrester. EST SUB with an integrated surge arrester
is available in two versions: the EST SUB SA for fixed
earth grids and the EST SUB SAC for coiled earth grids.
The advantages
at a glance
n
n
n
n
Combined cable termination and
protection from over voltage
Quick and easy to mount
Oil and gas-free
Leak-proof
New: Dry IXOSIL cable
termination with surge
arrester
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19
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M2016-013 INT 04 / 2016 Art Direction: VISCHER & BERNET, Stuttgart We accept no liability for printing errors / Subject to technical modifications
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